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SHEET METAL WORK 



BY 



Marion S. Trew 

Instructor in Sheet Metal Work 

Washington Junior High School 

Rochester, New York 

AND 

Verne A. Bird 

'•Director of Industrial Arts 
Rochester, New York 



DRAWINGS BY 

Robert H. Barnes 

AFTER SKETCHES BY 

Marion S. Trew 



(Copyrighted 1920) 



Privately Printed and Distributed 



•^7 



^OV 10 1920 



©CU601980 



**t> I 






SHEET METAL is a term applied to various kinds of metals 
rolled into sheet form. The commonest kinds are sheet 
iron, galvanized iron, tin plate, zinc, copper, brass and 
aluminum. We have also the more precious metals such as 
gold and silver in sheet form. A special line of tools and 
skilled workmen are required to work these different kinds 
of metals into forms to meet the requirements of a large and 
growing industry. 

Sheet metal work is an important factor in the industrial 
world, especially in connection with the building trades which 
require the roofing, skylight, ventilating, heating and ceilings 
to be of sheet metal, and in large fire proof buildings the metal 
trim has even taken the place of the wooden casings and doors. 
Much furniture is now also made of sheet metal. 

The tin roofing has been extensively used for a great 
many years. It was first imported from Europe about one 
hundred years ago and the first tin plate made in America 
was manufactured in Philadelphia in 1830. Records show 
that the roof laid in 1835 on the Horace Binney residence is 
still in place and there are many instances where roofs laid 
forty and fifty years ago are at present in a good state of 
preservation. It is economical on account of its lightness and 
durability and affords the best protection against fire, and is 
easily repaired. After it is once put on it requires but little 
attention excepting occasionally a coat of paint. 

Then there is the automobile, aeroplane and sheet metal 
boat industries all of which offer a wide field of opportunity 
to the young men who possess the necessary training. 



GALVANIZED IRON 

Galvanized iron is black iron or steel coated with zinc or 
spelter, as it is called by manufacturers, — for the purpose of 
protecting it by a coating of metal that will not readily oxidize 
when exposed to the weather. The black sheets are dipped 
in great vats filled with a pickling bath of sulphuric acid solu- 
tion that eats off the cinder and scale that remain on the 
sheets. They are then washed with clear water and taken to 
the galvanizing department, dipped into a bath of molten 
spelter, and passed while hot through squeezing rolls that 
removes superflous metal. As the sheet emerges from the 
hot spelter it presents a plain silvery surface, but the instant 
the cooling begins the spelter crystalizes. 

A standard gauge is used for uncoated sheets. Add 2 Yi 
ounces per square foot for the weight of the coating to the 
finished galvanized sheet. 



ZINC 

Zinc, also commonly known as spelter, is a hard, bluish 
white metal. It is extracted from ores by a process of dis- 
tillation. At ordinary temperatures it is somewhat brittle 
but becomes very malleable when heated above a temperature 
of 212 degrees, so that it may be rolled into thin sheets and 
easily worked in presses. It is extensively used in the manu- 
facture of artistic work, such as making casts of statues, orna- 
mental cornice, and other trimmings on buildings. Another 
important use of zinc is in the manufacture of electric bat- 
teries. 



TIN 

Tin is a soft rather malleable metal. It is white, crystal- 
line, rather inactive, not readily uniting with the oxygen of 
the air. 

Tin is mostly obtained from ore called tin stone, which 
is an oxide of tin. This ore is yellow, red, gray and black and 



strikes fire with steel. The dressing of the ore is a difficult 
dperation. It yields only from ten to eighty-five pounds of tin 
oxide to a ton of material, and it is so scattered through the 
ore that it has to be reduced to a powder and thoroughly 
washed to rid it of its impurities. It is then put through a 
process of smelting, after which it is drawn off and cast into 
bars called block tin. The largest supply of tin ore comes 
from the East Indies, Bolivia and Cornwall. 

It must have been one of the earliest metals known as it 
was used in the bronze of which the oldest weapons and tools 
were made. 

Since tin does not oxidize in air it is used as a protective 
coating on sheet iron. So long as this coating remains intact 
the iron is protected from rusting. If, however, the tin layer 
is damaged the iron rusts rapidly underneath. 

Copper vessels used for cooking purposes are coated with 
tin to prevent the poison from the copper getting into the 
food. Some compounds of tin are often added to silk and 
various other fabrics to render them non-inflammable, and, in 
the case of silk, to give weight. It is also rolled into very thin 
sheets called tin foil., 

The manufacture of tin plate is about the same as that 
of galvanized iron. The base plate is made from ingots 
poured into a smaller size, then rolled into sheets and sheared 
to the desired size. These sheets must then go through the 
process of pickling, washing, annealing, and second pickling, 
then be thoroughly washed and covered with a coating of pure 
tin. 

Tin plate is designated as IC or furnace tin, IX, IXX, 
IXXX, meaning one cross, two cross, etc. 

Tern plate which is generally known as roofing tin is coated 
with an alloy consisting of approximately 75 per cent lead and 
25 per cent tin. Tern plates are known by the amount of 
coating that is contained on a box of plates or 112 sheets. 
Thus 8 lb., 12 lb., 20 lb., or 40 lb., this meaning for a 20 lb. 
coated sheet, 20 pounds of coating was used on a box of 112 
plates. 



COPPER 

Records show copper to have been one of the first metals 
brought into use by mankind. 

It was known to the Romans as Cyprum, probably for 
the reason that the Phenicians found large mines of copper 
on the island of Cyprus and discovered the art of working it. 

The primative smiths also discovered the art of making 
an alloy of copper and some other metal, generally assumed to 
be tin, of which weapons and tools could be made hard enough 
to cut the hardest rock. These tools have been found in the 
graves of some ancient Celtic races, and were probably used 
in the construction of their temples. 

Copper is moderately hard and highly tenacious; takes 
a brilliant polish, and is about nine times heavier than water. 
It is the best known conductor of electricity. 

The various weights of sheet copper are designated by 
the number of ounces contained in a square foot of the sheet, 
that is — 14 ounce copper is of such thickness that it weighs 
14 ounces to the square foot of sheet copper. 



ALLOYS 

An alloy is a combination of two or more metals. Alloys 
have additional properties which do not exist in either of the 
metals used in their making. 

Copper and zinc are alloyed together in the manufacture 
of brass, a most common and useful metal. Soft solder is an 
alloy of lead and tin. Other hard solders are alloys of zinc, 
copper and silver, different proportions of which are used to 
make them the required degree of hardness. 

Bronze is an alloy of copper and tin, a metal long used 
by the ancients for weapons and utensils ; it is now widely used 
for statues, bells and machinery. An alloy called bronze is 
also produced by the combination of aluminum and copper. 
There are many other varieties of bronze having different pro- 
portions of metals, — lead, silver and zinc are sometimes added. 



SOLDERING 

Soldering is a process of uniting two pieces of metal by 
means of using an alloy having a lower fusion point than the 
metals to be joined. Broadly speaking the term soldering is 
applied to three processes known as soft soldering, hard solder- 
ing or brazing, and lead burning. Lead burning is not truly 
a soldering process as the edges of the metals are actually 
welded together by means of a blow pipe flame. 

Soft soldering, or soldering as done by the sheet metal 
worker, is done by using the soldering copper (sometimes 
miscalled the soldering iron). The solder used is known as 
half and half and is composed of tin and lead, and is suitable 
for soldering galvanized iron, copper, brass, zinc, and iron. 
The melting point of solder varies according to the quality, 
usually between 400 and 500 degrees Fahrenheit. 

The soldering copper before it can be used must be tinned. 
The first operation is to remove the oxide and dirt by using a 
file until the copper is smooth and bright; next heat the cop- 
per to a temperature a little more than required for soldering 
but not red hot; then clean the copper with a piece of sala- 
moniac, at the same time applying a little solder to the cleaned 
surface which instantly adheres on coming in contact with it. 
Another method is to file the copper until it is thoroughly 
clean and bright; slightly hollow one side of a piece of soft 
brick ; put some rosin in the hollow part ; heat the copper to a 
point when it will just melt the solder (care must be used not 
to heat the copper too hot as it will instantly oxidize and then 
cannot be tinned with rosin until it has again been filed) ; 
melt a few drops of solder in the rosin and rub the copper 
briskly in the melted rosin and solder until the copper is thor- 
oughly tinned. The copper must not be overheated or the 
tinning will be destroyed and will have to be retinned before 
it can again be used. 

Fluxes are used to prevent the metals which are being 
soldered from oxidizing, and to clean the surfaces and aid the 
fusion of the solder to the metals. The most common flux is 
Hydrochloric (Muriatic) acid and rosin. Hydrochloric acid 
in the raw state is used in soldering galvanized iron and zinc. 



Chloride of zinc, or cut acid as it is usually called by the 
sheet metal worker, is prepared by dissolving all the zinc in 
hydrochloric acid that it will hold in solution. It may then 
be diluted with water according to the strength required. A 
solution of equal parts of gylcerine, water, and chloride of zinc 
makes a very good flux for certain metals, the glycerine to 
some extent preventing corrosion which is likely to take place. 
In soldering metals with acid, or a flux which contains acid, 
the work must be thoroughly cleaned after soldering or cor- 
rosion will immediately take place. Rosin should always be 
used for soldering tin and it is much better to use rosin or a 
good soldering compound for soldering new brass and copper. 

MEASUREMENT 

There are two systems of measure used in this country, 
namely : The English system and the Metric system. The one 
most used at the present time is the English system, the metric 
system being used chiefly in laboratory work and in the manu- 
facture of articles for export to countries using the metric 
system. 

However, it is interesting to know that no standard of 
length for the English system has ever been formally legalized 
by our government, and the metric bar, the ultimate unit of 
comparison for the metric system, has been legally adopted 
by our congress. 

This ultimate standard serves not only for divisions of 
the metric system but for the English foot and yard as well. 
Our standard yard is defined as 3600/3937 of a meter, — in 
other words a length equal to the standard meter is divided 
into 39.37 parts called inches and 36 of them equal our stand- 
ard yard. 

The fact that the English system was in general use in 
this country before the adoption of the metric system is no 
doubt responsible for its continued use. 

The legal or standardized unit of comparison in the metric 
system for linear measure is the meter, which is divided into 
ten equal parts called decimeters. Each decimeter is then 



subdivided into ten equal parts which are called centimeters 
and the centimeters are divided into ten parts called milli- 
meters. The greatest advantage of the system is at once 
apparent from the method of subdivision which is known as 
the decimal system or division by tens. 

In the English system the standard unit of linear measure 
is the yard, which is divided into three equal parts called feet. 
The next subdivision is the inch and there are twelve inches 
to the foot. The. inch we find divided into halves, quarters, 
eighths and sixteenths on the common rules or instruments of 
measurement and down to thirty-seconds, sixty-fourths and 
one-hundredths of an inch on the steel scale. The steel scale 
is used mostly by machinists and other mechanics who are 
doing very accurate work. The principal difference between 
the two systems is in the method of subdividing the standard 
unit, one using the decimal and the other the fractional system. 

THE YARD STICK is an instrument commonly con- 
structed of one piece of hard wood about 3/16" by 1" with 
brass tips at the ends and usually graduated only to eighths of 
an inch. It is well proportioned for the measurement of a 
room in the home, or in the store where it is used in measuring 
dry goods. 

THE TWO FOOT RULE is perhaps the most widely used 
instrument of linear measure where great accuracy is not re- 
quired. It is usually made of boxwood and so constructed that 
it will fold up in a six inch length. Boxwood possesses a delicate 
yellow color and is much used in the manufacture of measur- 
ing rules, mathematical instruments and musical instruments 
because of its very dense structure and fine uniform grain. 
It is also hard and resists wear better than most woods. The 
edges of the rule, with the exception of the cheaper grades, 
are faced with thin strips of brass to prevent wear and inac- 
curacy. The rule has four different graduations, the differ- 
ence being only in the subdivisions of the inch. The gradua- 
tions are usually eighths, sixteenths and twelfths. The cus- 
tomary system of marking the graduations on the two foot 
rule is from right to left. The reason for this is that when 
marking off a distance the rule is generally held in the left 



hand and the end of the rule is used as a stop for the pencil 
in marking the object. 

The reducing scale on the two foot rule is used for getting 
dimensions from a blue print that has been drawn to scale. 



THE MICROMETER 

The micrometer is an instrument which makes an appli- 
cation of the principle of the screw in measurement. Meas- 
urement by the micrometer depends upon the direct relation 
between the number of revolutions of the screw and the dis- 
tance traveled by it. The object to be measured is placed 
between a fixed point called the anvil and a movable part 
called the spindle. 

One end of the spindle is threaded with a fine thread hav- 
ing a pitch of l/40th of an inch. That is, there are 40 of these 
threads to one inch. Attached to the threaded end of the 
spindle is a cup shaped piece called the thimble. This thimble 
is knurled on the outside so that it may be used to turn the 
spindle. When the instrument is assembled the thimble slides 
down over part of the frame which is threaded to match the 
thread on the spindle and acts as a guide for it. This part 
is called the sleeve and on it will be found a system of lines 
or divisions which when used in connections with a set of divi- 
sions on the beveled edge of the thimble, will indicate the longi- 
tudinal distance traveled by the spindle and the number of 
revolutions made by both the thimble and spindle. Now, 
knowing as we do, the pitch or lead of the screw, it is easy to 
determine the measurement or distance between the spindle 
and anvil for any setting. 

In adjusting the micrometer for a measurement first open 
until the jaws are far enough apart to admit the object 
to be measured, then close by turning the small ratchet head 
on the end of the thimble. This ratchet is so adjusted that it 
will slip when too much pressure is applied. The use of the 
ratchet will also insure a uniform pressure on all measure- 
ments. When the ratchet is not used it is easy to turn the 



spindle up so tightly that it will spring the jaws enough to 
cause an error in the measurement, if not to ruin the instru- 
ment. 



VERNIER SCALE 
(f?EAD/NG=.0005 ") 



A B 



M/CftOME TEH 



C a 





A-FRAME D- SLEEVE 
B- ANVIL E-THIMBLE 

C-5PINDLE F- RATCHET 



To Read the Micrometer. 

(See drawing of micrometer). The vertical divisions on 
the sleeve are divided into l/40th parts of an inch, which in 
the decimal form is .025. There are also 40 threads to the 
inch on the spindle so that one complete revolution of the 
thimble causes the spindle to travel just one scale division. 
Every fourth line is made longer, and starting from zero 
there are ten of these lines to the inch, so in taking a reading 
they indicate tenths of an inch. Now it is plain that if one 
revolution of the thimble moves the spindle .025 of an inch, 
1/25 of a revolution or one division on the thimble will move 
it 1/25 of .025 or one one-thousandth part of an inch. Thus 
if the position of the thimble is as shown in drawing we have 
18 divisions showing on the horizontal scale and the thimble 
is 13 divisions past the zero position, and our reading would 
be 18 X .025 plus the .013 on the thimble or 18 X -025 = .450 
and .450 + .013 = .463 of an inch. 



If the instrument has a VERNIER scale in addition to 
the one mentioned above it will read to a ten-thousandth part 
of an inch. You will notice that there are ten longitudinal 
divisions on the sleeve and that they are smaller than the 
divisions on the thimble, the ten on the sleeve being equal to 
nine on the thimble, making the difference between the length 
of one of the ten and one of the nine divisions equal to one- 
tenth of a division on the thimble. We found the thimble 
divisions to be one one-thousandth of an inch so 1/10 of 1/1000 
will be 1/10000 making the reading taken from the vernier 
or longitudinal scale in the ten-thousandths of an inch. Thus 
if there were five divisions showing on the horizontal scale 
and a little over three on the thimble scale you would have 
5 X .025 or .125 + .003 on the thimble or .128 inches. But 
the reading on the thimble was, in this case, a little more than 
three so we must add to the .128 the vernier reading which is 
found by following along the thimble until you come to a line 
which exactly coincides with one on the vernier scale. In this 
case it is line five, which since the divisions are in ten-thou- 
sandths, is .0005 of an inch. This reading we must add to the 
above reading, making it .128 -f- .0005 or .1285 of an inch for 
the final reading. 



LOCKED SEAM 
Specifications 

Exercise in seaming, using scrap stock. Two pieces of 
galvanized iron each 2" x 6" are to be seamed together with a 
Vs" lock. 



Ft 6. 7 



//<?. 2. 




Standard Practice Instructions 

Watch carefully the instructor's demonstration, showing 
correct use of the squaring shears, hand groover, and folding 
machine. 

1. Cut two pieces of galvanized iron, each 2" x 6". 

2. Set folding machine so as to turn a %" sharp lock. Turn 

one long edge of each piece. (Fig. 1.) 

3. Lock pieces together (Fig. 2), and groove with a No. 4 

hand groover. (Fig. 3.) 

Questions for Oral Discussion 

1. How much stock is used in making this seam? 

2. Why is a No. 4 hand groover used in making a VJT seam? 



CLIPPED SEAM 
Specifications 

Exercise clipping seam. Seam is to be clipped on one end 
for wiring and the other end clipped for burr. After having 
determined the amount of stock used in making the locked 
seam clip the two corners for the wired end of the seam %" 
down and in enough so that clipped edges will meet without 
overlapping. (Figs. 1-2.) 

Make about a 60 degree cut for the burred end of the 
seam so the corners will meet without overlapping. (Figs. 
1-2.) 






\ / 



/\ 



Fie./ 



F,o.2 



RIVETED SEAM 
Specifications. 



Exercise in riveting, using scrap stock. Two pieces of 
galvanized iron 3" x 12" are to be riveted together, lap to be 
%", IV2 lb. rivets are to be used and placed 2" apart. 



-1/ r-i? 



12- 

Fig. 7. 



"T)«D ! 



m 




Fig 2 



Fig. j 



-*■ 



Fi Mi shed Joint. 



Finished Rivet 



Standard Practice Instructions 

1. Cut two pieces of galvanized iron 3" x 12" having all corners 

square. 

2. Mark a line %" in along one long side of each piece (Fig. 1) . 

3. Mark off with prick punch as shown in (Fig. 2). 

4. Punch holes with solid punch at the prick marks, using a 

piece of wood to punch on. 

5. Place pieces together with burr side of holes up (Fig. 3), 

and rivet as shown by instructor by beginning at the 
ends and finishing at the center. 



RIVETED SEAM 
Questions to be Answered in Note Book 

1. What is the thickness of No. 26 galvanized iron in decimal 

parts of an inch? (Use Micrometer.) 

2. What is the meaning of the term 1 lb. rivets? 

3. What are the sizes of rivets generally used in sheet metal 

shops ? 

4. How is a Micrometer read? (Show by sketch.) 

5. In what parts of an inch is a two foot rule usually divided? 

6. What is the difference between a Solid punch and a Prick 

punch? For what purpose should each be used? 

7. Why do we use a No. 4 rivet set on this model? 



WIRED EDGE 
Specifications 

Exercise in wiring, using scrap stock. One piece of gal- 
vanized iron 2" x 6" is to have a piece of No. 11 wire 6" long 
rolled in one long edge. Wire is to be entirely covered by the 
galvanized iron. 




Standard Practice Instructions 

1. Cut a piece of galvanized iron 2" x 6" having all corners 

square. 

2. Set folding machine so that it will turn over an edge of the 

metal sufficient to cover a No. 11 wire. 

3. Place the long edge of the metal in machine and turn the 

edge, (Fig. 1) as shown by instructor in demonstra- 
tion. / 

4. Cut piece of No 11 wire 6" long. 

5. Place wire in the turned edge of the metal, (Fig. 2) and 

finish covering the wire, using wiring machine. 
(Fig. 3.) 

Questions to be Answered in Note Book 

1. Why is wire placed in the edge of sheet metal? 

2. Find the diameter in decimal parts of an inch of No. 11 

wire. 

3. How much stock is used in covering No. 11 wire? 

4. Can any other machine be used beside the wiring machine 

in rolling the metal over small wire? 

5. What tool do we use to find the size of wire ? 

6. How is the folding machine set to turn the edge for wire? 



SEED BOX 



Specifications 

Seed box is to be made of No. 26 or No. 28 galvanized 
iron ; corners are to be riveted with 1 lb. rivets ; No. 13 wire is 
to be placed around edge of box; corners are to be soldered. 





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Standard Practice Instructions 

1. Cut blank 10" square. 

2. Draw lines A-B and C-D 2" from each edge. 

3. Draw line E-F 1/2" from line A-B in each corner as shown. 

(Fig. 1.) 

4. Draw lines G-H half way between lines AB and EF. 

(Fig. 1.) 

5. Draw lines K-L %" from CD (Fig. 1). 



SEED BOX 
Standard Practice Instructions — Continued 

6. Make prick mark in center of the lines G-H and K-L. 

(Fig. 1.) 

7. Measure in %" from A and B and make dots. (Fig. 1.) 

8. From these dots draw short oblique lines at an angle of 30° 

to the horizontal to meet the lines E-F. (Fig. 1.) 

9. Draw similar oblique lines at an angle of 30° to the horizon- 

tal from the corners 0. (Fig. 1.) 



V 



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10. Cut out corners. (Fig. 2.) 

11. Punch holes for rivets at prick marks in the center of the 

lines G-H and L-K. 
Break sides at 45° along lines A-B and C-D. 

12. Turn all edges for No. 13 wire, having edges so that wire 

will be on outside of finished box, using folding 
machine. 

13. Finish forming on square stake using hands and mallet. 

14. Form laps around sides and rivet. 



SEED BOX 
Standard Practice Instructions — Continued 

15. Cut wire 1" longer than the distance around the top of box. 

16. Bend wire to exact size of top of box using vice and ham- 

mer. The joint in the wire should come about 1" from 
a corner. 

17. Turn edge over wire using mallet and pliers. 

18. Set wire down with machine. 

19. Solder corners. 

Questions to be Answered in Note Book 

1. Find the thickness of No. 28 galvanized iron in decimal 

parts of an inch. 

2. By referring to Follansbee Bros., or Apollo shop card find 

the weight per sq. ft. of No. 26 and No. 28 galvanized 
iron. 

3. Which size of hand shears did you use in cutting the metal? 

4. About how much are shears of this size worth? 

5. By what other name are shears somtimes called? 

6. Why are rivets tinned? 

7. How many sheets are there in a bundle of No. 28 galvan- 

ized iron? 

8. How many sq. in. of metal are there in this model? 

9. What is the average weight per bundle of No. 28 galvan- 

ized iron? 
10. Make a freehand drawing of this model. 



QUART MEASURE 
Specifications 

Quart measure is to be made of No. 28 galvanized iron; 
top edge is to be wired with No. 13 wire; bottom is to be 
seamed on. Bottom and side seams are to be soldered. 



Turn for wire- 




Standard Practice Instructions 

1. Cut stock 37/ 8 " wide, 16*4" long. 

2. Clip upper corners for wire and lower corners for burr. 

(See Fig. 1.) 

3. Set folder %" for lock and place piece in machine with side 

clipped for wire toward left and turn lock in opposite 
directions on ends of piece. (Fig. 2) . 

4. Set Folder for turning edge for wire. (Fig. 2). See in- 

structor. 

5. Cut wire to required length. 

6. Put wire in place and finish with wiring machine ; drive it 

through y<£\ (See Fig. 2), from the end on which the 
lock is turned toward the wire. 

7. Form to shape, having wire on outside, by placing wired 

edge in grooves at right hand end of rolls. 

8. Groove seam with No. 4 Groover or as otherwise directed. 



QUART MEASURE 
Standard Practice Instructions — Continued 





F/g. 3 



Turn 

TactTwJFfr~50lder burr 
Fig. 4. 




Fig 5" 




Fig. 7. 



9. Turn V6" burr on bottom and tack seam with solder near 
bottom to keep seam from slipping apart. (Fig. 4.) 

10. Cut circle for bottom *4" larger in diameter, than diameter 

over burr. 

11. Turn burr on bottom with burring machine. (Fig. 5.) 

12. Set down bottom with setting down machine. 

13. Seam bottom up on seaming stake using mallet. (Fig. 6.) 

14. Solder bottom seam with bottom soldering copper and side 

seam with pointed soldering copper, using clear muria- 
tic acid. 



QUART MEASURE 
Questions to be Answered in Note Book 

1. How is a soldering copper tinned? 

2. Why is it tinned? 

3. What kind of acid is used in soldering galvanized iron? 

4. Of what metals is solder composed? 

5. By what firm are the burring machine and the forming 

machine made? 

6. What are the lengths of the rolls in the forming machine ? 

7. What is the diameter and depth of a quart measure? 

8. Which end of the double seaming stake is used in seaming 

a quart measure? 

9. What kind of a soldering copper is used in soldering the 

bottom ? 
10. Make a free hand sketch of the quart measure. 



BISCUIT CUTTER 
Specifications 

Biscuit cutter is to be made of IC or IX bright tin and to 
be 2V2" in diameter and IV2" in height, having seam lapped 
i/4" and handle double hemmed. Top edge to be wired. 



Standard Practice Instructions 

1. Cut stock 8 3/16" x 1%". 

2. Clip corner on one end for wire. (Fig. 1.) 

3. Place wire in long side clipped for same. 

4. Form to shape and solder lapped seam. 

5. Cut handle IV2" in width and equal in length to one-half of 



6. 

7. 



the circumference of cutter, allowing %' 



extra in 
Clip ends 



length for soldering under wire. (Fig. 2). 

of handle. (Fig 2). 
Turn double hem on sides of handle. 
Form handle to shape and solder to cutter as shown in 

sketch. 




■SOI DER 





50LPERED 



P 



no / 



no 2 



'8 



COOKIE CUTTER 
Specifications 

Cookie cutter is to be 3^" in diameter and to have rim 
wide. The rim is to be corrugated and handle to be double 



hemmed. 



Standard Practice Instructions 



1. Cut circle for top 3 11/16" in diameter and turn small burr 

on same. 

2. Punch a 1" hole in center of top. 

3. Cut piece for rim and corrugate it by running it through 

gears of forming machine. (See instructor.) 

4. Fit rim to top ; solder ends together and fasten in place by 

soldering in several places. 

5. Cut piece for handle 5*4" long by IV2'' wide. 

6. Double hem sides of handle. 

7. Form handle to a semicircle and solder to top. 



50L PER 




DUST PAN 
Specifications 

Dust pan is to be made of No. 26 galvanized iron. Cor- 
ners are to be riveted with 1 lb. rivets. Handle is to be seamed 
and riveted to bottom of pan. 



OA 



a 



oc 



>T> 



°G 



O 



Inside 



D° 



M° 



M 
Fl<5. 1. 



DUST PAN 



Standard Practice Instructions 

1. Cut stock for dust pan 12*4 " x 1314". 

2. Mark corners and holes and cut as per pattern. (Fig. 1). 

3. Indicate holes A-B-C-D-E-F-G-H as shown on 

sketch and punch with a solid punch for rivets. 

4. Indicate marks 1-2-3-4-5 and 6 with sharp prick punch 

and punch hole X with %" hollow punch for handle. 

5. Mark lines 1 to 2, 2 to 3, and 3 to 4, as shown on sketch. 

6. Make a light crease on lines 1-2-3 and 4 with beading 

machine. 

7. Place word "inside" as shown on sketch. 

8. Place word "outside" on opposite side of metal. 

9. Turn 3/16" hem on edge M towards back with folding 

machine set for a sharp edge. (Fig. 2)-(l). 

10. Turn 3/16" hem on edge L towards inside. (Fig. 2) -(2). 

11. Turn edges N-N (Fig. 1), 3/16" on folding machine set 

for wired edge and place No. 13 wire in same edges 
(Fig. 2)-(3). 




Rivet 



DUST PAN 
Standard Practice Instructions — Continued 

12. Bend up sides at 60 degrees on lines 1-2 and 3-4 using 

cornice brake. (See instructor.) (Fig. 2) -(4). 

13. Bend on line 2-3 using hands, square stake and mallet. 

(Fig. 2)-(5). 

14. Bend laps on prick marks 5 and 6 and place inside. 

(Fig. 3). 

15. Rivet corners together. (Fig. 3). 

16. Bend top piece to place using cornice brake and pliers. 

(See instructor.) (Fig. 4). 

17. Rivet top piece to sides. (Fig. 4). 

18. Make handle like pattern and rivet in place. (Fig. 4). 

Questions to be Answered in Note Book 

1. How many sheets of No. 26 galvanized iron are there in a 

bundle? 

2. What is the average weight per bundle of No. 26 galvan- 

ized iron? 

3. What machines were used in making this model that were 

not used in making the quart measure? 

4. Where were these machines made ? Give the approximate 

cost of them. 

5. How long a piece of metal can be put in the cornice brake? 

6. How long a piece of metal can be put in the folding ma- 

chine? 

7. Are there longer folding machines and cornice brakes 

made? 

8. What is the length and cost of the cutting nippers used in 

this shop? 

9. Of what kind of wood are tinners' mallets made? 
10. Make a free hand sketch of dust pan. 



TEN QUART WATER PAIL 
Specifications 

Pail is. to be made of No. 26 galvanized iron ; top edge is 
to be wired with No. 6 wire ; handle is to be of No. 6 wire ; pail 
is to be thoroughly soldered. 




(bet pattern from Instructor 




Turn locks 



Turn for 
Wire^ 




Snap 

on - 
bo ttorn"^ — &iurn burr 

Fig. 4. 



omplefed 
Fie. 5. pail 



Standard Practice Instructions 

1. Get out stock for body according to pattern. 

2. Clip upper corners for wiring and lower corners for burr. 

(See Fig. 1). 

3. Turn %" locks for side seam in opposite directions. 

(Fig. 2). 

4. Form to shape on forming machine. (Fig. 2). 

5. Groove seam on grooving machine. 



WATER PAIL 
Standard Practice Instructions — Continued 

6. Turn burr on bottom edge. (Fig. 3). 

7. Turn upper edge for wire. (Fig. 3). 

8. Form wire on forming machine. 

9. Place wire in top and wire with wiring machine. (Fig. 4) . 

10. Solder side seam on the inside. 

11. Cut out bottom i/4" larger than diameter over burr and 

turn y 8 " burr on it. (Fig 4) . 

12. Snap on bottom. (Fig. 4). 

13. Set down bottom with setting down machine. 

14. Seam bottom on double seaming machine. 

15. Solder bottom and side seams. 

16. Rivet on ears directly opposite each other. (Fig. 5). 

17. Form bale and put in place. (See instructor.) (Fig. 5). 



Questions to be Answered in Note Book 

1 What are the diameters of No. 6 and No. 10 wire? 

2. In what divisions is the scale on the circle shears marked? 

3. How does this scale compare with the actual scale on a 

rule? 

4. What are the largest and smallest size circles that this 

machine will cut? 

5. What is the heaviest gauge iron this machine is made to 

cut? 

6. What is the thickness in decimal parts of an inch, and how 

many pounds per sq. foot does this gauge iron weigh? 

7. What is the cost of the circle shears? 

8. What machine do we use in turning the edge of the pail for 

the wire? 

9. About how much is this machine worth? 

10. Make in note book a freehand drawing of the pail turned 

upside down. 

11. How many bottoms can be cut from a sheet of iron... 

x ? 

12. How many sq. ft. of iron in bottoms? 

13. How many sq. ft. of iron in a sheet of iron x ? 

14. How much waste in cutting bottoms from a sheet 

x ? 

15. What % of waste in cutting bottoms from a sheet 

x ? 



FLOUR SCOOP 
Specifications 

Flour scoop is to be made of IC bright tin. Back is to be 
burred and snapped on body of scoop and neatly soldered. 
Handle to have a false wire edge. 




Standard Practice Instructions 

(Watch carefully the instructor's demonstrations of sol- 
dering on tin.) 

1. Get out stock for body of scoop according to pattern. 

2. Form to shape on forming machine. (Fig. 1). 
Solder body together with ends lapping 14". (Fig. 1). 
Cut back 3/16" larger than end of body. 
Turn 3/32" burr on back. (Fig. 2) . 
Snap back on body. (Fig. 3). 
Solder on outside. (Fig. 3). 
Cut out handle according to pattern. 



3. 

4. 
5. 
6. 

7. 
8. 



9. Turn edges 3/16" for false wiring. 



Pa.Tti.rn -for Scoofo 
( Half 5/3e) 



' 



M^^BBH^HMi 



FLOUR SCOOP 
Standard Practice Instructions — Continued 

10. Turn down false wire with turning machine. 

11. Form handle on stake. (Fig. 4). 

12. Solder handle on back of scoop. (Fig. 5). 




Solder 



Fig i. 




Cross 
section 
of back 

Fie 2 



Cross section 

showing 
back snapped 
over body 



F/o j 



Fig 4 




Form handle 
ho this Shape 



Fio t> 



Questions to be Answered in Note Book 

1. What is the size of a sheet of tin plate and how many are 

there in a box? 

2. Of what is tin plate composed? 

3. Would the term "a sheet of tin" be correct in referring 

to this metal? 

4. How many flour scoops of the small pattern can be made 

from a sheet of tin? 

5. What is the current price of IC bright tin per box? 

6. From what sources can we find out the current price of tin ? 

7. What flux is used in soldering the tin? 

8. How is this flux prepared? 

9. What is the thickness of IC tin in decimal parts of an inch? 



FUNNEL 
Specifications 

Sixty degree funnel is to be made out of IC or IX tin or 
No. 26 galvanized iron. Top of funnel is to be wired with No. 
11 or No. 13 wire. 



18O 




no. 6 



LOCK & OftOOl/E 



Standard Practice Instructions 

1. Watch carefully the demonstration by instructor of the 

turning of the locks for the seam, also the fitting of the 
body and the forming of the wire ring. 

2. Set dividers for the radius of the semicircle to diameter 

of the top of the required funnel, plus 14" for No. 13 
wire. (Fig. 1). 

3. Place dividers 3/16" from the edge of blank and strike 

semicircle, this 3/16" allowing for locks. (Fig. 1). 

4. Set dividers to the diameter of the hole required for the 

spout of the funnel, and using the same center as 
before strike small semicircle on pattern. (Fig. 2). 

5. Cut out blank for body and clip upper corners for wire 

and lower corners for spout. (Fig. 2). 



FUNNEL 
Standard Practice Instructions — Continued 

6. Turn edges for locks in opposite directions. (Fig. 3). 

7. Form to shape on blow horn stake. (Fig. 4). 

8. Lock edges together and groove, using No. 4 hand groover. 

(Fig. 4). 

9. Turn top edge for wire and place wire in top of funnel. 

(Fig. 8). 

10. Develop pattern for spout as shown in (Fig. 5) and cut 

out same. 

11. Form spout to shape having edges lap %", using blow horn 

stake, and solder lapped edges together. (Fig. 6). 

12. Solder spout to body of funnel, having seam of spout in 

line with the seam of the funnel. (Fig. 8) . 

13. Form %" ring of wire (Fig. 7) (See instructor), and 

fasten to funnel by loop placed under wire at the seam. 
(Fig. 8). 

Questions to be Answered in Note Book 

1. What is iron ore? 

2. Is it usually found pure? 

3. What are the common impurities that are most harmful to 

the finished material? 

4. Where are the largest deposits of iron ore found in this 

country? How many tons are mined yearly? 

5. How is the ore mined in this district? 

6. How is the ore shipped from the mines? 

7. Where is it sent? 



TIN CUP 
Specifications 

Tin cup is to be made of IC bright tin. Bottom is to be 
double seamed. Top is to be wired with No. 13 wire. 





BEND HANDLE 
TO APPPOX/- 
MATEL Y rp/5 
SHAPE 



6P100I/E 
TH/55EAM 



Ji 



TOP ED6E POP MED 
'- [POP W/P/NG^ 



fiO 5 
CH055 SECT- 
ION OP CUP 



W~~l 



sTUfW ONE ED6E ffACX 
TUPN ONE ED6E POPWADD 







L J 



bupff on bottom edge 
Bottom snapped on 



ft 6.6 
CP055 5PCT/ON OE 
BOTTOM W/TH BOPPED EDO,. 



Standard Practice Instructions 

(Watch carefully the instructor's demonstration of the 
method of turning a false wired edge on the handle and the 
forming of same.) 

1. Get out stock for body of cup allowing 14" on top edge for 

wiring, %" on bottom for double seam and 1/2" more 
than circumference for lock. (Fig. 1 or sketch of 
blank) . 

2. Cut upper corners of blank for wire. (Fig. 1-A). Cut 

lower corners of blank for seam. (Fig. 1-B) . 

3. Turn Vh" sharp lock on ends of piece in opposite directions 

for side seam. (Use folding machine). 

4. Turn 3/16" round edge on upper edge for wire and put 

wire in place, having wire project V2 " beyond the end 
on which the lock is turned from the wire. 



TIN CUP 
Standard Practice Instructions — Continued 

5. Place wired edge in small grooves at right hand end of 

forming tool and form to shape having wire on outside. 

6. Lock ends together and groove with a No. 4 hand groover. 

7. Pound down seam with mallet and solder seam on the 

inside. 

8. Turn burr on bottom edge for seam. 

9. Cut bottom 3/16" larger than diameter over burr. 

10. Turn burr on bottom with burring machine. (Fig. 6). 

11. Snap bottom on side piece and set down with setting down 

machine. 

12. Seam up bottom with seaming machine or by hand. 

13. Cut stock for handle according to sketch. (Fig. 7). 

14. Turn edges for false wiring on handle and form to shape 

in small rolls. 

15. Solder bottom on inside of cup. 

16. Solder handle on cup at the side seam. 

Questions to be Answered in Note Book 

1. How many of these completed cups can be made from a 

sheet of IC tin 20" x 28"? 

2. What is the meaning of the term IC tin? 

3. When are other terms used? 

4. How is acid prepared to solder on tin? 

5. For what other purpose is this acid used? 



CANTEEN 
Specifications 

Canteen is to be made 6%" in diameter, of IC bright tin. 
Sides are to be raised and burred and carefully soldered to a 
1" rim. 



d 



ffl 



J-L. 



5 



/y£*? 



(6§.xrr) 



r-J 



3 " SOLDER 

k/i 





_r^_ loop roff 
/ZhLJ^ w/f ? E ping 

ft 6. 7 



Standard Practice Instructions 

(Watch carefully the demonstration by instructor as to 
the proper use of the raising hammer.) 

1. Cut two circles for the sides. (Fig. 1). 

2. Using the raising hammer and block, raise the sides about 

%". 

3. Turn 3/32" burr on sides. 

4. Cut piece for rim 1" in width and equal in length to the 

circumference of the sides, allowing 14 " f° r l a P- Punch 
%" hole in center of piece for spout. (Fig. 2) . 

5. Form rim to shape and solder ends together. 

6. Solder sides on rim. (Fig. 3). 

7. Cut piece for spout 1" in width and equal in length to the 

circumference of a %" circle allowing i/°," for lap. 
(Fig. 4). 



CANTEEN 
Standard Practice Instructions — Continued 

8. Turn %" hem on one side of piece and form to shape, hav- 

ing hem on inside. (Fig. 4 and 5) . 

9. Solder seam of spout and solder spout to canteen. 

10. Make 2 wire rings (Fig. 6) and 2 loops (Fig. 7) and solder 
to rim on opposite sides of the spout about 3" from 
the spout. 

Questions to be Answered in Note Book 

1. What is a blast furnace? 

2. For what purpose it is used? 

3. Describe the stove of the blast furnace and its use. 

4. What materials are used in connection with the ore and 

how is it reduced to a liquid state? 

5. What is the use of the limestone? 

6. What is slag? 

7. How is molten iron released and how much at one filling? 

8. Describe the manner in which the slag and the molten iron 

is removed. 

9. What is the product of the blast furnace called ? 



BREAD TIN 
Specifications 

Bread tin is to be made of IC bright tin. The corners 
are to be folded around the ends and a No. 13 wire is to be 
placed in the top edge. 




Fie. 2 

S/DE v/rw 
Fio.J 



Standard Practice Instructions 

1. Cut stock for bread tin equal in length and width to the 

bottom plus height (E) for sides and ends, allowing 
!/4" (F) for wire. 

2. Mark size of bottom and draw line A-l. 

3. Make lines A-2. These lines determine the flare of the pan. 

4. Set dividers at a radius less than the height of the pan 

and using (A) for a center strike arc G-H. 

5. On arc G-H make the distance between 4 and 5 equal to 

that between 3 and 4. 

6. Draw line A-L through point 5. 

7. Make the distance A-M equal to the distance A-L. 

8. Repeat this layout on other corners. 

9. Cut out corners 1 - 2 - M. 



BREAD TIN 
Standard Practice Instructions — Continued 

10. Bend up sides slightly with hand folder (see instructor). 

(See Fig. 1 end view). 

11. Bend ends in like manner. (Fig. 2 end view). 

12. Crease corner on hatchet stake, using hands only. (Fig. 3). 

13. Draw up sides and ends until corners are formed. 

(Fig. 4). 

14. Fold corners around ends, using mallet. (Fig. 5). 

15. Turn upper edge for wire, using edge folder. 

16. Bend wire to shape and size of pan top. 

17. Put wire in place and finish with wiring machine. 



DIPPER 
Specifications 

Dipper is to be made of IX bright tin. 
quart. 



Capacity one 




6055 



H/INDLE 



Standard Practice Instructions 

1. Develop pattern for body to size required. Refer to table 

for size. (See page 56). 

2. Cut stock as directed and clip upper corners for wire and 

lower corners for burr. 

3. Form to shape and groove seam. 

4. Place wire in top and turn %" burr for bottom. 

5. Cut bottom and turn burr. 

6. Seam bottom on, and solder dipper. 

7. Make handle to size as directed by instructor and solder to 

dipper. 



-4 



LARGE SIZE WATER PAIL 
Specifications 

Water pail is to be made of No. 26 galvanized iron; top 
edge to be wired with No. 6 coppered market wire; bottom 
edge to be wired with, No. 10 wire; bottom to be set •%" up 
from bottom edge ; handle to be made of %" rod. 




METHOD OF FORM/NG 
W/RE 8/^/L 




F/a? 

Standard Practice Instructions 

1. Cut stock for body according to pattern. 

2. Clip upper corners for No. 6 wire and lower corners for 

No. 10 wire. 

3. Turn locks in opposite direction. 

4. Form to shape in forming machine. 

5. Groove seam on grooving machine. 

6. Turn upper edge for No. 6 wire and lower edge for No. 10 

wire. 

7. Cut and form wires and place in top and bottom edges. 

8. Run a swedge in the proper place ; also run a 3/16" bead on 

outside of pail %," from the bottom edge. (Fig. 1). 

9. Cut bottom 14" larger in diameter than diameter at ex- 

treme part of pail in the bead. 

10. Turn Vs" burr on bottom and force bottom in place in bead 

and solder pail. 

11. Rivet ears over seam at top of pail. 

12. Cut bail; form to shape, and put in place. (See cut for 

forming bail). 



-; 



GROCERS HAND SCOOP 

Specifications 

Scoop is to be made of No. 26 galvanized iron. The back 
is to be raised. It is to have a well proportioned handle 
soldered to back. 




Standard Practice Instructions 

1. Cut out body and handle for scoop according to pattern 

developed. 

2. Turn Vs" locks on ends ; form to shape and groove seam. 

3. Cut circle for back 7/16" larger in diameter than diameter 

of scoop. This allows for the raising of the back. 

4. Raise the back to about V2" in height. 

5. Turn %" edges on back and snap on body of scoop. 

6. Solder on back ; form handle and solder in place-. 

7. Make boss for handle as per pattern, and solder to scoop. 



FLARING LIQUID MEASURE 
r 

Specifications 

Measure is to be made of IX bright tin or material selected 
by instructor. The measure is to hold one-half gallon. The 
upper edge is to be wired with No. 13 wire and the bottom 
double seamed to the body. The handle and lip must be in good 
proportion to the body. The handle is to have wired edges. 




Standard Practice Instructions n 

1. Develop pattern for body and lip measure by referring to 

drawing and table for method and size. 

2. Cut stock, properly clip corners for wire and burr. 

3. Place wire in upper edge and form to shape. 

4. Groove seam together, turn burr for bottom and solder 

side seam. 

5. Cut bottom, turn burr and double seam to body. 

6. Make handle and lip to size as directed by instructor. 

7. Hem upper edge of lip (using burring machine) and wire 

edges of handle. 

8. Solder handle and complete measure by soldering bottom. 



WINDOW BOX 
Specifications 

Window box is to be made of Nor. 26 galvanized iron. It 
is to have an inside false bottom for ventilating and drainage 
and y% double edge projecting around top of box. Corners 
are to be mitered and stayed. 




or FA/O 





ne z 




/M5/DE BOTTOM ■ F/6 3 




±1 



Standard Practice Instructions 

1. Cut stock for sides and bottom in one piece allowing for 

top edge. (See Fig. 1 for dimensions). 

2. Form to shape in cornice brake. 

3. Cut out ends to pattern developed. (Fig. 2). 

4. Tack ends in place with solder and finish by riveting. 

5. Make inside bottom according to sketch. (Fig. 3). 

6. Solder box water tight. 



OILY WASTE CAN 
Specifications 

Waste can is to be made 12" x 12" x 14". 14" is the height. 
It is to be made of No. 26 galvanized iron ; it is to have four 
legs; the cover is to close automatically. 



PATTER A/ FOR 
LEO 
6 




Standard Practice Instructions 

1. Cut stock for body of can equal to dimensions given in 

specifications allowing for No. 6 wire on top and on 

seam. 
Form to shape ; lock seam and place wire in top edge. 
Cut bottom 1" larger all around than size of can. 
Cut corners as shown in sketch and fold edges to shape. 

(Fig. 1). 
Place bottom on can and fasten with solder and rivets. 
Make hinged cover and handle as shown in sketch. 

(Fig. 2). 
Fasten cover to can using 3/32" x y 2 " round stove bolts. 
8. Make four legs and rivet to each corner of can. (See Fig. 

3 for dimensions.) 



2. 

q 

3. 



5. 

6. 

7. 



STAIN CABINET 

Specifications 

Stain cabinet is to be made of No. 26 galvanized iron ; to 
be 28" high, 28" wide, and 14" deep ; to have two shelves ; door 
to be made double and riveted to cabinet with two 3" Tee 
hinges; also to have a latch fastener. The top is to project 
IV2" beyond cabinet on front and ends; back to be straight. 




P/l TTEFIN FOR L EG5 

He. J 



Standard Practice Instructions 

1. Cut stock 28" in width and equal in length to the sum of 

the lengths of the back, ends, front plus inside projec- 
tions for the door. (Fig. 1). 

2. Make bottom with front edge double, projecting down 1" ; 

back and ends to be made 1" single edge. 

3. Lay out top for mitered corners ; form to shape and solder 

corners. (Fig. 2). 

4. Make shelves same as bottom excepting 1" narrower to 

allow for inside projection for door. 



STAIN CABINET 
Standard Practice Instructions — Continued 

5. Cut legs to the dimensions as shown in sketch. (Fig. 3). 

6. Assemble cabinet, using 3/32" x %" stove bolts or metal 

screws. 

7. Make door as shown in sketch (Fig. 4), having it lap V2" 

all around on cabinet ; rivet on hinges and bolt hinges 
to cabinet. 

8. Make door latch as shown in sketch. (Fig. 5). 



GARBAGE CAN 



Specifications 

Capacity 8V£ gallons. Diameter 14". Sides of can are 
to be made of No. 26 galvanized iron; bottom is to be made 
of No. 24 galvanized iron, to be set up 1" with edge turned 
over a band (1" x 1/16") iron, band to be riveted to body of 
can. Handle is to be of %" rod. Pitched cover is to be made 
with a IV2" pitch, rim of cover to be finished 114" deep with 
a No. 10 wire in edge. 




Fjo.P 



Standard Practice Instructions 

1. Cut stock to required dimensions and clip corners as 

shown. (Fig. 1). 

2. Turn locks in opposite directions on pipe folding machine, 

having edge clipped 1" placed to the right. 

3. Turn edge V2" at right angles on side clipped 1" and place 

3/16" rod or No. 6 wire in edge, rod to project 1" 
beyond the end on which the lock is turned from the 
rod. 

4. Form to shape in forming machine with rod on outside. 

5. Lock together and groove with a No. 1 groover. 

6. Run two swedges in the proper place in the can. (Fig. 2) . 



■ ' "* 



GARBAGE CAN 
Standard Practice Instructions — Continued 

7. Run small bead on outside of can 1%" from bottom. 

(Fig. 2). 

8. Cut bottom %" larger in diameter than diameter of can 

at inside of bead. 

9. Turn 3/16" edge on bottom and snap into can with burr 

side down ; solder sides and bottom. 

10. Cut 1" band for bottom; clamp into can and mark for 

. proper length. 

11. Rivet band in place and turn metal extending below over 

band. 

12. Cut rim for cover 1%" in width, and 3" longer than cir- 

cumference of can outside of wire. 

13. Form rim to shape and make it %" longer than circumfer- 

ence outside of wire, allowing 2" for lap. 

14. Clip one end for wire and burr ; rivet ends together ; place 

wire in one edge and turn 3/16" burr on other side. 

15. Refer to drawing for pitch cover, and finish cover with 

handle. (See page 55). 



OIL FILTER 



Specifications 

Oil filter for the purpose of filtering engine oil through 
water and cotton waste. It is to be made of No. 26 galvan- 
ized iron. Size: 10" in diameter and 14" high. A Vs" faucet 
is to be placed 5" up from the bottom to drain off the oil. 
Cover is to be made with a 1" pitch, t/i" mesh screen is to be 
placed in bottom of waste receptacle. 



WA5TF RFCfPTA CL £ 




PERFORATED 
D/SC^ 




^-ruez 



no./ 



r~/6. 



c 



Standard Practice Instructions 

1. Cut stock for body of pail equal to the circumference of a 

10" diameter and 14" in height, allowing for No. 6 
wire on top and all seams. (Fig. 1). 

2. Cut upper corners for wire and lower corners for burr. 

3. Turn i/&" locks on end of piece and place No. 6 wire in top, 

wire to project 1" beyond the end on which the lock 
is turned from the wire. 

4. Form to shape and groove seam. 

5. Turn -V&" burr on bottom edge. 



OIL FILTER 

Standard Practice Instructions — Continued 

6. Cut circle for bottom ; turn burr and seam in place. 

7. Develop patterns for receptacle to hold the waste. 

(Fig. 2). 

8. Turn locks; form to shape; place No. 10 wire in top and 

seam on cone shaped bottom. 

9. Make y% tube long enough to reach from waste receptacle 

to within 14" from bottom of pail. 

10. Cut disc 9V2" diameter and perforate with l /s" holes. 

11. Turn burr on edge of disc. 

12. Cut V2" hole in bottom of receptacle and solder tube in 

place. 

13. Cut V2'' hole in center of disc and solder on lower end of 

tube having burred edge of disc down. 

14. Cut hole in side of pail 5" from bottom and solder faucet 

in place. 

15. Rivet ears on pail ; form bail and put in place. 

16. Make cover by referring to drawing for pitched covers on 

Page 55. 



MINNOW PAIL 

Specifications 

Minnow pail is to be made double, of No. 26 galvanized 
iron. Inside pail is to have an air chamber for floating" the 
pail. Lower part of inside pail is to be made of Vfr" mesh 
galvanized screen secured to a galvanized iron bottom. 



RA/5ED COl/ER 




F/HTEP/SJ FOR 
//VS/PE OE ELO/\T 




FLO/IT 



6AL\/AA//ZEP P/\N 



Standard Practice Instructions 

1. Cut stock for body of pail equal to the circumference of a 

10%" diameter, and 11" in height allowing for a No. 
7 wire on top and all seams. (Fig. 1). 

2. Refer to oil filter for instructions for making pail. 

3. Develop pattern for air chamber according to sketch. 

(Fig. 2). 

4. Solder seams together air tight. 

5. Make pan with a 1" rim for bottom equal in diameter to 

the bottom part of air chamber. 

6. Cut screen to required size and solder in place. 

7. Make cover and bail for top of inside pail and fasten in 

place. 



ASH CAN 
Specifications 

Ash can is to be made of No. 24 galvanized iron. Bottom 
is to be set up 2" with the edge turned over a band 2" x Va" 
iron, iron band to be riveted to body of can and to project V2" 
below can bottom. Body of can is to have a %" rod around 
bottom and a No. 6 wire around top. A 1V2'' x %" band to be 
placed around inside of top edge and to project V2" above top. 
Top band is to be riveted to can. Bottom is to be soldered 
inside. Handles are to be properly placed on sides of can. 




Handle 
5 wedge 

2 "Band 



Fig. 2 



Fig. J. 



Standard Practice Instructions 

1. Cut stock 24" x 57 V2" and clip ends as shown. (Fig. 1) . 

2. Turn locks in opposite directions on pipe folding machine, 

having side clipped 2" placed to the right. 



ASH CAN 

Standard Practice Instructions — Continued 

3. Turn edge 11/16" at right angles on side clipped 2" (using 

cornice brake) and place a %" rod in same edge. Rod 
is to project IV2" beyond the end on which the lock 
is turned from the rod. 

4. Form to shape in forming machine with rod on the out- 

side. (Fig. 3). 

5. Lock together and groove with a No. 1 had groover. 

6. Turn edge for No. 6 wire in large turning machine and 

form wire to size and place in same edge. (See In- 
structor). (Fig. 2). 

7. Run 4 s wedges in the proper places in the can. (Fig. 2). 

8. Run small bead on the inside of the can 1" from the top 

edge. (Fig. 2). 

9. Run small bead on the outside of the can IV2" from the 

bottom edge. (Fig. 2). 

10. Cut piece for the bottom 19" square and cut a 18%" circle 

from this piece, and turn burr on same. 

11. Cut two bands for can 57" long, one band l 1 /?" x %" for 

the top and one band 2" x 1/8 " for the bottom. (Fig. 4) . 

12. Clamp bands in can and mark to proper length. 

13. Take bands and cut on mark for length and punch holes 

about 6" apart near one edge of band. (Fig. 4) . 

14. Place bands in can and rivet in place. (Fig. 2). 

15. Rivet handles under second swedge from top of can, one on 

the seam and other on the opposite side. (Fig. 3). 



Questions to be Answered in Note Book 

1. How many square feet of metal used in making this can? 

2. What is the weight per foot of IV2" x Va" and 2" x 1/8 " band 

iron? 

3. Using table weights of galvanized iron and band iron, 

find weight of this can. 

4. What is the melting point of the following metals — Solder, 

Lead and Tin? 



ASH CAN 
Questions to be Answered in Note Book — Continued 

5. Of what is galvanized iron composed? 

6. What is a tinner's rule? 

7. For what purposes can it be used? 

8. About what is the retail price of ash cans? 

9. What is the cost at current prices of the material used in 

making an ash can? 



SOME PRACTICAL GEOMETRICAL PROBLEMS USED IN SHEET 

METAL WORK 



TO BISECT AN ANGLE 




L 

TO LOCATE THE MITER 
LINE IN A TWO PIECE ELBOW 



ANY AN OLE INSCRIBED IN 

A SEMICIRCLE 15 A RIGHT 

ANGLE 




METHOO OF L OCAT- 
ING EARS OF PAULS 



F 



£. 






2d 



TO CONSTRUCT AN 
OCTAGON 



TO DESCRIBE AN 
OCTAGON 




TO CONSTRUCT 
A HEXAGON 




TO CON5TRUCT AN EL L 'P5£ 
WITHIN A GIVEN RECTANGLE 



DEVELOPMENT OF PATTERNS FOR PITCHED COVERS 




Cf-g = a-b) (cd = o-l) 

(6-H*C-0) (m-i -- O-L) 
LINE X-X TAN6ENT TQ ARCS 





or: 


>' r 




\ c *- 




b\ 





5CALE-3* A/7" 



DIMENSIONS FOR FLARING PAILS, DIPPERS AND 
LIQUID MEASURES 

In making liquid measures it is necessary that care be 
observed as to accuracy in the dimensions and the develop- 
ment' of the patterns. Before they can be used for commer- 
cial purposes they must be sealed by the proper officials. 

The following schedule gives dimensions commonly used 
by sheet metal workers: 



Size 



1 Gallon 
y 2 Gallon 
1 Quart 
1 Pint 



i/ 2 Pint 



Liquid 


Measures 


Top 


Bottom 


Diameter 


Diameter 


Inches 


Inches 


5. , 


6.50 


3.45 


5.18 


2.75 


4.12 


2.14 


3.75 


2. 


2.50 



Height 
Inches 

8.875 

7.78 

6.18 

4.25 

3.625 



Dippers 



Size 

1 Quart 

2 Quart 



Top 

Diameter 

Inches 

5.25 

7. 



Bottom 

Diameter 

Inches 

4 
5 



Height 
Inches 

3.75 
4.75 



Paih 





Top 


Bottom 


Height 


Size 


Diameter 


Diameter 






Inches 


Inches 


Inches 


17 Quarts 


12.50 


10 


10 


14 Quarts 


11.50 


8 


10.875 


10 Quarts 


10.125 


7.875 


9.25 


8 Quarts 


10 


6.50 


8.50 


6 Quarts 


8 


6 


8.93 


4 Quarts 


7.50 


5.25 


7.25 


2 Quarts 


6 


5 


5 



APPROXIMATE GAUGE NUMBER FOR COPPER 





u. s. 






u. s. 




Ounces per 


Gauge 


Thickness 


Ounces per 


Gauge 


Thickness 


Square Foot 


Number 


Inch 


Square Foot 


Number 


Inch 


5 


38 


.00685 


28 


20 


.03835 


6 


35 


.00821 


30 


19 


.0412 


7 


33 


.00958 


32 


19 


.0438 


8 


31 


.01095 


34 


18 


.0465 


9 


30 


.01232 


36 


18 


.0494 


10 


29 


.01370 


40 


17 


.0549 


11 


28 


.01547 


44 


16 


.0604 


12 


27 


.01693 


48 


15 


.0658 


13 


26 


.01780 


52 


15 


.0712 


14 


26 


.01917 


56 


14 


.0767 


15 


25 


.02052 


60 


14 


.0822 


16 


25 


.02185 


64 


13 


.0876 


18 


24 


.02465 


72 


12 


.0984 


20 


23 


.02748 


80 


12 


.1095 


22 


22 


.03015 


88 


11 


.1205 


24 


22 


.03290 


96 


10 


.1315 


26 


21 


.03551 


s 







GAUGES AND WEIGHTS OF SHEET ALUMINUM 





Thickness 


Weight per 




Thickness 


Weight per 


No. 


Inch 


Square Foot 


No. 


Inch 


Square Foot 


0000 


.46 


6.406 


19 


.036 


.5 


000 


.41 


5.704 


20 


.032 


.445 


00 


.365 


5.08 


21 


.028 


.396 





.325 


4.524 


22 


.025 


.353 


1 


.289 


4.029 


23 


.023 


.314 


2 


.258 


3.588 


24 


.02 


.28 


3 


.229 


3.195 


25 


.018 


.249 


4 


.204 


2.845 


26 


.016 


.222 


5 


.182 


2.534 


27 


.014 


.197 


6 


.162 


2.256 


28 


.013 


.176 


7 


.144 


2.009 


29 


.011 


.157 


8 


.128 


1.789 


30 


.01 


.14 


9 


.114 


1.594 


31 


.009 


.124 


10 


.102 


1.418 


32 


.00795 


.1107 


11 


.091 


1.264 


33 


.00708 


.0985 


12 


.081 


1.126 


34 


.0063 


.0877 


13 


.072 


1.002 


35 


.0056 


.0782 


14 


.064 


.892 


36 


.005 


.0696 


15 


.057 


.795 


37 


.00445 


.062 


16 


.051 


.708 


38 


.00396 


.0552 


17 


.045 


.63 


39 


.00353 


.0491 


18 


.04 


.561 


40 


.00314 


.0429 



U. S. Standard Gauge. 



WEIGHT AND LENGTH OF WIRE 



Diameter 


Wire Gauge 


Diameter 


Weight of 


Feet in 


Inches 


No. 


Inches 


100 Ft. Lbs. 


63 Lbs. 


9/32 


1 


.283 


21.23 


296 




2 


.263 


18.34 


343 


1/4 


3 


.244 


15.78 


399 


7/32 


4 


.225 


13.39 


470 




5 


.207 


11.35 


555 


3/16 


6 


.192 


9.73 


647 




7 


.177 


8.03 


759 


5/32 


8 


.162 


6.96 


905 




9 


.148 


5.08 


1,086 




10 


.135 


4.83 


1,304 


1/8 


11 


.120 


3.82 


1,649 




12 


.105 


2.92 


2,158 




13 


.092 


2.24 


2,813 




14 


.080 


11.69 


3,728 




15 


.072 


1.37 


4,598 




16 


.063 


1.05 


6,000 




17 


.054 


.97 


8,182 




18 


.047 


.58 


10,862 




19 


.041 


.45 


14,000 




20 


.035 


.32 


19,687 




21 


.032 


.27 


23,333 




22 


.028 


.21 


30,000 




23 


.025 


.175 


36,000 




24 


.023 


.140 


45,000 




25 


.020 


.116 


54,310 



APPROXIMATE GAUGE AND WEIGHT OF ZINC 
Illinois Zinc Company's Standard Gauge 



Gauge 
Number 


Weight per 

Square Foot 

in Pounds 


Thickness 
Inch 


U. S. Gauge 
Number 


3 


22 


.00587 


38 


4 


30 


.008 


35 


5 


37 


.011 


32 


6 • 


45 


.012 


30 


7 


52 


.014 


29 


8 


60 


.016 


28 


9 


67 


.018 


26 


10 


75 


.020 


25 


11 


90 


.024 


24 


12 


1.05 


.028 


23 


13 


1.20 


.032 


22 


14 


1.35 


.036 


20 


15 


1.50 


.040 


19 


16 


1.68 


.045 


19 


17 


1.87 


.050 


18 


18 


2.06 


.055 


17 


19 


2.25 


.060 


16 


20 


2.62 


.070 


15 


21 


3.00 


.080 


14 


22 


3.37 


.090 


13 


23 


3.75 


.100 


12 


24 


4.70 


.125 


11 


25 


9.40 


.250 


3 


26 


14.00 


.375 


00 



WEIGHT OF BLACK SHEET IRON 

For galvanized sheet iron add 21/2 ounces per square foot. 



Thickness 


Thickness in 


Weight per 


Weight per 


of 


Fractions 


and Decimal 


Square Foot 


Square Foot 


Gauge 


Parts 


of an Inch 


in Ounces 


in Pounds 


10 


9-64 


.1406 


90 


5.625 


11 


1-8 


.125 


80 


5. 


12 


7-64 


.1093 


70 


4.375 


13 


3-32 


.0937 


60 


3.75 


14 


5-64 


.0781 


50 


3.125 


15 


9-128 


.0703 


45 


2.812 


16 


1-16 


.0625 


40 


2.5 


17 


9-160 


.0562 


36 


2.25 


18 


1-20 


.05 


32 


2. 


19 


7-160 


.0437 


28 


1.75 


20 


3-80 


.0375 


24 


1.50 


21 


11-320 


.0343 


22 


1.375 


22 


1-32 


.0312 


20 


1.25 


23 


9-320 


.0281 


18 


1.125 


24 


1-40 


.025 


16 


1. 


25 


7-320 


.0218 


14 


.875 


26 


3-160 


.0187 


12 


.75 


27 


11-640 


.0171 


11 


.687 


28 


1-64 


.0156 


10 


.625 


29 


9-640 


.0140 


9 


.462 


30 


1-80 


.0125 


8 


.5 


31 


7-640 


.0109 


7 


.437 


32 


13-1280 


.0101 


6 1/2 


.406 



iff! 



fir BH^B $88* 

P PBgmilr xffir iff W J 






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